Wiring module

ABSTRACT

A wiring module includes a flat line that is mounted on a power storage element group including power storage elements and a line-side connector that is to be fitted to a device-side connector included in a control unit of the power storage element group. The flat line includes an extra section extending from the power storage element group and a bending restricting plate is disposed on a portion of the extra section.

TECHNICAL FIELD

The technology disclosed herein relates to a wiring module.

BACKGROUND ART

A wiring module to be mounted on power storage elements that isdescribed in Japanese Unexamined Patent Application Publication No.2015-156329 has been known. The wiring module includes a voltagemonitoring line at an electrode post of the power storage element. Thevoltage monitoring line includes a connection line having flexibilitysuch as a flexible flat cable (FFC) or a flexible printed circuit board(FPC). A connection connector is connected to one end of the voltagemonitoring line. The connection connector is connected to a device-sideconnector included in a voltage monitoring unit.

RELATED ART DOCUMENT Patent Document

[Patent Document 1] Japanese Unexamined Patent Application PublicationNo. 2015-156329

SUMMARY OF THE INVENTION Problem to be Solved by the Invention

The connection connector is fitted to the device-side connector asfollows, for example. The power storage element including the wiringmodule is fixed in a predefined position and the device-side connectoris fixed in a predefined position. The connection connector is movedcloser to and opposite the device-side connector and pushed into thedevice-side connector. Thus, the connection connector and thedevice-side connector are fitted to each other.

In performing the above fitting operation, the voltage monitoring linenecessarily includes an extra section having a length required for theconnection connector to be moved closer to and opposite the device-sideconnector and a length required for the connection connector to bepushed into the device-side connector. The extra section is necessarilymoved to follow the connection connector during the fitting operation ofthe connection connector and the device-side connector.

However, if the voltage monitoring line is configured such that theextra section can be always moved freely, the extra section and theconnection connector may be moved and come into contact with a foreignobstacle. For example, any problems may be caused in the extra sectionor the connection connector due to vibrations caused in transportationof the wiring module before the fitting operation of the connectionconnector and the device-side connector. Furthermore, for example, anyproblems may be caused in the extra section or the connection connectordue to vibrations caused in transportation of the wiring module afterthe connection connector and the device-side connector are fitted toeach other and mounted on a vehicle.

The technology described herein was made in view of the abovecircumstances. An object is to provide a wiring module that suppressesan extra section from moving freely as necessary.

Means for Solving the Problem

The technology described herein is related to a wiring module includinga flat line that is mounted on a power storage element group includingpower storage elements and is one of a flexible printed circuit boardand a flexible flat cable, and a line-side connector that is connectedto an end portion of the flat line and to be fitted to a device-sideconnector included in a control unit of the power storage element group.The flat line includes an extra section extending from the power storageelement group and a bending restricting plate is disposed on a portionof the extra section.

According to the above configuration, the portion of the extra sectionwhere the bending restricting plate is disposed is less likely to bebent. This suppresses the extra section from moving freely due tovibrations. Therefore, the extra section is less likely to be deformedor come in contact with any obstacles. On the other hand, the portion ofthe extra section where the bending restricting plate is not disposed isallowed to move to follow the movement of the line-side connector.

Embodiments of the technology described herein may preferably includeconfigurations as follows.

The extra section may include a first bending portion and a secondbending portion and the first bending portion may be closer to thedevice-side connector with respect to the bending restricting plate andthe second bending portion may be closer to the power storage elementgroup with respect to the bending restricting plate. At least one of thefirst bending portion and the second bending portion may have a curvedsurface.

According to the above configuration, even if the positions of the powerstorage element group and the device-side connector do not correspond toeach other, one of the first bending portion and the second bendingportion having a curved surface is deformed and warped to absorb such aposition displacement.

The extra section may be folded at the first bending portion and have acurved surface at the second bending portion.

According to the above configuration, it is clear that the portionextending from the first bending portion to the device-side connectorcorresponds to a stroke length necessary for the fitting to thedevice-side connector. This improves operation efficiency for fittingthe line-side connector to the device-side connector.

The flat line may include an extended section that extends outwardlyfrom a side edge thereof and the extended section may be connected to abus bar at an end thereof and the bus bar may be connected to at leastone of electrode terminals included in the power storage elements.

According to the above configuration, the extended section of the flatline is connected to the bus bar that is connected to the electrodeterminal of the power storage element. Therefore, compared to theconfiguration including multiple lines for detecting voltages of thepower storage elements, the space can be saved.

Advantageous Effects of Invention

According to the technology disclosed herein, an extra section of a flatline is suppressed from moving freely as necessary.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view illustrating a power storage moduleaccording to a first embodiment.

FIG. 2 is a partial enlarged side view illustrating a line-sideconnector and a device-side connector that are fitted to each other.

FIG. 3 is a perspective view illustrating a separator.

FIG. 4 is a perspective view illustrating a power storage element groupincluding power storage elements that are arranged in the separator.

FIG. 5 is a perspective view illustrating the power storage elementgroup where a wiring module is mounted and the wiring module includingan extra section of a flat line.

FIG. 6 is a partial enlarged view illustrating the extra section of theflat line.

FIG. 7 is a perspective view illustrating a holding member.

FIG. 8 is a partial enlarged side view illustrating the power storagemodule including the extra section that is bent at a first bendingportion and a second bending portion.

FIG. 9 is a plan view illustrating the power storage module before theline-side connector and the device-side connector are fitted to eachother.

MODES FOR CARRYING OUT THE INVENTION First Embodiment

A first embodiment of the technology disclosed herein will be describedwith reference to FIGS. 1 to 9. A power storage module 10 according tothis embodiment includes a power storage element group 12 includingpower storage elements 11 and a wiring module 13 that is mounted on thepower storage element group 12. The power storage module 10 is used as adriving power of a vehicle such as an electric vehicle, a hybridvehicle, and a plug-in hybrid vehicle or a power for built-in electriccomponents. In the following description, a Z-direction corresponds toan upper side, a Y-direction corresponds to a front side, and anX-direction corresponds to a left side. A symbol is put on only one ofthe same components and the symbol may not be put on other ones.

Power Storage Module 10

The power storage module 10 includes the power storage element group 12including the power storage elements 11 and the wiring module 13 that ismounted on the power storage element group 12. The power storage element11 has a parallelepiped shape that is flat in a left-right direction.The power storage element 11 includes electrode terminals 14 on frontand rear end portions of an upper surface, respectively. The electrodeterminal 14 has a rectangular shape seen from the above. Out of the twoelectrode terminals 14 included in one power storage element 11, one isan anode terminal and another one is a cathode terminal. The powerstorage elements 11 are arranged in the left-right direction such thatthe adjacent electrode terminals 14 have different polarities.

Separator 15

As illustrated in FIG. 4, the power storage elements 11 are arranged ina separator 15 that is made of insulating synthetic resin. Asillustrated in FIG. 3, the separator 15 has a rectangular shape seenfrom the above. The separator 15 includes arrangement sections 16. Eachof the arrangement sections 16 has a shape that is same as or slightlygreater than an outer shape of each power storage element 11 such thateach power storage element 11 can be arranged in each arrangementsection 16. The arrangement sections 16 are arranged in the left-rightdirection. The adjacent arrangement sections 16 are defined byseparation walls 17. The separation walls 17 electrically insulate thepower storage elements 11 arranged in the respective arrangementsections 16.

The separator 15 includes disposing sections 19 (two disposing sectionsin this embodiment) where flat lines 18 (described later) are arranged.The disposing sections 19 are spaced from each other. The disposingsections 19 extend from a left edge to a right edge of the separator 15.Each disposing section 19 includes two slits 20 in the left-edgeportion. The two slits 20 extend in a front-rear direction and arearranged at an interval in the left-right direction. A holding member21, which will be described later, is fit to hole edges of the slits 20and attached to the separator 15.

Holding Member 21

As illustrated in FIG. 7, the holding member 21 is made of insulatingsynthetic resin. The holding member 21 includes a top plate portion 22having a rectangular shape seen from the above and leg portions 23extending downwardly from four corners of the top plate portion 22,respectively. Each of the leg portions 23 has a stopper protrusion 24that protrudes from a lower end of the leg portion 23 outwardly withrespect to the front-rear direction. The stopper protrusions 24 come incontact with the hole edges of the slits 20 of the disposing section 19from a lower side and the holding member 21 can be attached to theseparator 15 so as not to be released from the slits 20 upwardly.

Bus Bar 25

As illustrated in FIG. 9, the adjacent electrode terminals 14 of thepower storage elements 11 that are arranged in the left-right directionare electrically connected to each other via a bus bar 25 made ofconductive metal. The bus bar 25 is electrically connected to theelectrode terminals 14 with a known method such as laser welding,soldering, and brazing. The bus bar 25 has a rectangular shape seen fromthe above. Metal for the bus bar may be selected as needed from copper,copper alloy, aluminum, and aluminum alloy, for example. A plated layermay be disposed on a surface of the bus bar 25. Metal for the platedlayer may be selected as needed from tin and nickel, for example.

Edge-Side Bus Bar 26

As illustrated in FIG. 9, out of the two electrode terminals 14 arrangedon the power storage element 11 that is disposed at a left end, theelectrode terminal 14 on the rear end is connected to an edge-side busbar 26. Out of the two electrode terminals 14 arranged on the powerstorage element 11 that is disposed at a right end, the electrodeterminal 14 on the rear end is connected to the edge-side bus bar 26.The edge-side bus bar 26 is connected to only one electrode terminal 14.The edge-side bus bar 26 is electrically connected to the electrodeterminal 14 with a known method such as laser welding, soldering, andbrazing. An external terminal, which is not illustrated, is electricallyconnected to the edge-side bus bar 26 such that power can be suppliedfrom the power storage module 10 to external circuits. Other than theconfiguration described above, the edge-side bus bar 26 includes thesame configuration as that of the bus bar 25 and will not be explained.

Flat Line 18

The wiring module 13 includes a front-side flat line 18A arranged on afront side and a rear-side flat line 18B arranged on a rear side. Thefront-side flat line 18A and the rear-side flat line 18B are spaced fromeach other with respect to the front-rear direction. In the followingdescription, the flat line 18 is generally referred without specifyingthe front-side flat line 18A or the rear-side flat line 18B. Thefront-side flat line 18A and the rear-side flat line 18B are flexibleprinted circuit boards or flexible flat cables. The front-side flat line18A and the rear-side flat line 18B in this embodiment are flexibleprinted circuit boards each of which includes an insulating film andconductive lines formed on the insulating film with a print wiringtechnology.

The front-side flat line 18A includes a body section 27 extending in theleft-right direction and extended sections 28 (seven extended sections28 in this embodiment) extending frontward from the body section 27. Theextended section 28 extends downwardly from the body section 27 at aright angle and is bent at right angle toward the front side. Thus, theextended section 28 has a shape of a crank. The front end portion of theextended section 28 is below the bus bar 25. The insulating film isremoved from a portion of the front end portion of the extended section28 corresponding to the bus bar 25 and the conductive line is exposedoutside. The exposed conductive line and the bus bar 25 are electricallyconnected to each other with a known method such as welding, soldering,and brazing.

The rear-side flat line 18B includes the body section 27 extending inthe left-right direction and extended sections 28 (eight extendedsections 28 in this embodiment) extending frontward from the bodysection 27. The extended section 28 extends downwardly from the bodysection 27 at a right angle and is bent at right angle toward the frontside. Thus, the extended section 28 has a shape of a crank. The rear endportions of the extended sections 28 on the right end and the left endare below the edge-side bus bars 26, respectively. Among the extendedsections 28, the rear end portions of the extended sections 28 otherthan the ones on the right end and the left end are below the bus bars25, respectively. The insulating film is removed from a portion of therear end portion of the extended section 28 corresponding to the bus bar25 or the edge-side bus bar 26 and the conductive line is exposedoutside. The exposed conductive line and the bus bar 25 or the edge-sidebus bar are electrically connected to each other with a known methodsuch as welding, soldering, and brazing.

As illustrated in FIGS. 5 and 6, the flat line 18 includes an extrasection 29 that extends leftward from a left edge portion of the powerstorage element group 12. A line-side connector 30 is connected to aleft end portion of the extra section 29. The line-side connector 30includes a terminal, which is not illustrated, therein. The terminal iselectrically connected to each conductive line of the flat line 18.

As illustrated in FIG. 2, the line-side connector 30 is fit in adevice-side connector 32 included in a control unit 31 to beelectrically connected to the control unit 31. The control unit 31receives signals related to the condition of the power storage elements11 through the flat line 18 and monitors the condition of each powerstorage element 11 based on the signals and controls charging anddischarging of the power storage module 10.

As illustrated in FIG. 6, a bending restricting plate 33 is disposed onan upper surface of the extra section 29. The bending restricting plate33 extends from a left side position from a right end of the extrasection 29 to a substantially middle position with respect to theleft-right direction. The bending restricting plate 33 is fixed to theflat line 18 with a known method such as bonding or heat melt welding.

The bending restricting plate 33 has a rectangular shape seen from theabove. The bending restricting plate 33 has a width dimension in thefront-rear direction that is same as or slightly smaller than the widthdimension of the flat line 18 in the front-rear direction. The bendingrestricting plate 33 is fixed to the flat line 18 while being disposedon the flat line 18. According to such a configuration, the flat line 18is less likely to be bent in an area where the bending restricting plate33 is fixed. The bending restricting plate 33 is made of appropriatematerial such as a synthetic resin plate or a metal plate. For example,polyester such as polyethylene terephthalate and polybutyleneterephthalate, polyamide such as nylon 6 and nylon 6, 6, and epoxy resincontaining glass fiber may be used as appropriate.

The extra section 29 includes a first bending portion 34 and a secondbending portion 35. The first bending portion 34 is closer to thedevice-side connector 32 with respect to the bending restricting plate33 and the second bending portion 35 is closer to the power storageelement group 12 with respect to the bending restricting plate 33. Theextra section 29 is arranged below the top plate portion 22 of theholding member 21 while being bent at the first bending portion 34 andthe second bending portion 35.

The extra section 29 of the flat line 18 is bent at the first bendingportion 34 at an acute angle seen from a side. In other words, the extrasection 29 of the flat line 18 is folded at the first bending portion34.

On the other hand, the extra section 29 of the flat line 18 is bent atthe second bending portion 35 in a curved shape seen from a side. Inother words, the second bending portion 35 has a curved surface.

As illustrated in FIG. 8, since the flat line 18 is moved in a directionof the arrow A to be closer to the control unit 31 at the first bendingportion 34, the portion of the extra section 29 of the flat line 18between the second bending portion 35 and the line-side connector 30becomes closer to the control unit 31. Accordingly, the line-sideconnector 30 can be connected to the device-side connector 32 of thecontrol unit 31.

One Example of Producing Process

Next, one example of a process of producing the power storage module 10according to the present embodiment will be described. The process ofproducing the power storage module 10 is not limited to the onedescribed below.

The line-side connector 30 is connected to the end of the flat line 18.The extended sections 28 of the flat line 18 are connected to the busbars 25 and the edge-side bus bars 26, respectively, with soldering, forexample. The bending restricting plate 33 is fixed to a predefinedposition of the flat line 18.

The power storage elements 11 are arranged in the respective arrangementsections 16 of the separator 15, respectively. The flat lines 18 aredisposed on the respective disposing sections 19 of the separator 15such that the electrode terminals 14 of the power storage elements 11overlap the bus bars 25 and the edge-side bus bars 26, respectively. Forexample, the electrode terminals 14 are connected to the bus bars 25 andthe electrode terminals 14 are connected to the edge-side bus bars 26,respectively, with laser welding.

The flat line 18 is gently bent at a portion that is on a right side ofthe bending restricting plate 33 to form the second bending portion 35.The flat line 18 is bent at a predefined portion at an acute angle toform the first bending portion 34.

The holding member 21 is attached to the separator 15 from an upper sideof the flat line 18 that is bent at the first bending portion 34 and thesecond bending portion 35. Accordingly, the flat line 18 is retainedbelow a base portion of the holding member 21 while being bent at thefirst bending portion and the second bending portion 35.

The power storage module 10 and the control unit are fixed topredetermined portions in a vehicle. The line-side connector 30 is movedcloser to the control unit 31 such that the flat line 18 is entirelymoved to a left side (in a direction illustrated by the arrow A) at thefirst bending portion 34. Thus, the line-side connector 30 is fitted tothe device-side connector 32 of the control unit 31.

Operations and Advantageous Effects of the Present Embodiment

Next, operations and advantageous effects of the present embodiment willbe described. The wiring module 13 according to the present embodimentincludes the flat line 18 that is a flexible printed circuit board or aflexible flat cable and the line-side connector 30 that is connected toan end portion of the flat line 18. The flat line 18 is mounted on thepower storage element group 12 including the power storage elements 11.The line-side connector 30 is to be fitted to the device-side connector32 included in the control unit 31 of the power storage element group12. The flat line 18 includes the extra section 29 that extends from thepower storage element group 12 and the bending restricting plate 33 isdisposed on a portion of the extra section 29.

According to the above configuration, the portion of the extra section29 where the bending restricting plate 33 is disposed is less likely tobe bent. This suppresses the extra section 29 from moving freely due tovibrations. Therefore, the extra section 29 is less likely to bedeformed or come in contact with any obstacles. On the other hand, theportion of the extra section 29 where the bending restricting plate 33is not disposed is allowed to move to follow the movement of theline-side connector 30.

Furthermore, in the present embodiment, the extra section 29 includesthe first bending portion 34 that is closer to the device-side connector32 with respect to the bending restricting plate 33 and the secondbending portion 35 that is closer to the power storage element group 12with respect to the bending restricting plate 33. At least one of thefirst bending portion 34 and the second bending portion 35 has a curvedsurface.

According to the above configuration, even if the positions of the powerstorage element group 12 and the device-side connector 32 do notcorrespond to each other, one of the first bending portion 34 and thesecond bending portion 35 having a curved surface is deformed and warpedto absorb such a position displacement.

According to the present embodiment, the extra section 29 is folded atthe first bending portion 34 and has a curved surface at the secondbending portion 35.

According to the above configuration, it is clear that the portionextending from the first bending portion 34 to the device-side connector32 corresponds to a stroke length necessary for the fitting to thedevice-side connector 32. This improves operation efficiency for fittingthe line-side connector 30 to the device-side connector 32.

According to the present embodiment, the flat line 18 includes theextended sections 28 extending outwardly from the side edge. The bus bar25 is connected to at least one of the electrode terminals 14 includedin the power storage elements 11.

According to the above configuration, the extended section 28 of theflat line 18 is connected to the bus bar 25 that is connected to theelectrode terminal 14 of the power storage element 11. Therefore,compared to the configuration including multiple lines for detectingvoltages of the power storage elements 11, the space can be saved.

Other Embodiments

The technology disclosed herein is not limited to the embodimentdescribed above and illustrated in the drawings. For example, thefollowing embodiments will be included in the technical scope of thetechnology.

(1) In the above embodiment, the wiring module 13 includes the holdingmember 21 that holds the extra section 29. However, the presenttechnology is not limited to this configuration and the holding member21 may not be included.

(2) In the above embodiment, the disposing section 19 is integrallyincluded in the separator 15. However, the present technology is notlimited to this configuration. The disposing section 19 included as acomponent separately from the separator 15 may be mounted on theseparator 15.

(3) In the above embodiment, the flexible printed circuit board is usedas the flat line 18. However, the present technology is not limited tothis configuration and the flexible flat cable may be used as the flatline 18.

(4) Only one flat line 18 or three or more flat lines 18 may beincluded.

(5) In the present embodiment, the extra section is bent at the firstbending portion 34 at an acute angle and gently bent at the secondbending portion 35. However, the present technology is not limited tothis configuration. The extra section may be gently bent at the firstbending portion and bent at the second bending portion 35 at an acuteangle. The extra section may be bent at an acute angle at the firstbending portion 34 and the second bending portion 35 or may be bentgently at the first bending portion 34 and the second bending portion35.

EXPLANATION OF SYMBOLS

11: power storage element

12: power storage element group

13: wiring module

14: electrode terminal

18: flat line

25: bus bar

26: edge-side bus bar

28: extended section

29: extra section

30: line-side connector

31: control unit

32: device-side connector

33: bending restricting plate

34: first bending portion

35: second bending portion

1. A wiring module comprising: a flat line that is mounted on a powerstorage element group including power storage elements and is one of aflexible printed circuit board and a flexible flat cable; and aline-side connector that is connected to an end portion of the flat lineand to be fitted to a device-side connector included in a control unitof the power storage element group, wherein the flat line includes anextra section extending from the power storage element group and abending restricting plate is disposed on a portion of the extra section.2. The wiring module according to claim 1, wherein the extra sectionincludes a first bending portion and a second bending portion, the firstbending portion is closer to the device-side connector with respect tothe bending restricting plate and the second bending portion is closerto the power storage element group with respect to the bendingrestricting plate, and at least one of the first bending portion and thesecond bending portion has a curved surface.
 3. The wiring moduleaccording to claim 2, wherein the extra section is folded at the firstbending portion and has a curved surface at the second bending portion.4. The wiring module according to claim 1, wherein the flat lineincludes an extended section that extends outwardly from a side edgethereof, the extended section is connected to a bus bar at an endthereof, and the bus bar is connected to at least one of electrodeterminals included in the power storage elements.